Mazda 6. Manual — part 116

FAN MOTOR

E–11

E

COOLING FAN MOTOR INSPECTION

A6E362215025W03

1. Verify that the battery is fully charged.
2. Connect battery positive voltage and an ammeter to the fan motor connector.
3. Verify that the fan motor operates smoothly at the standard current draw.

• If not as spcifid, replace the fan motor.

End Of Sie

TERMINAL No.

B

A

COOLING FAN HARNESS
CONNECTOR

LF

COOLING FAN
MOTOR No.1, 2

L3

COOLING FAN
MOTOR No.1

No.2

A

B

A

B

A

A

B

B

A

B

OR

A6A0112W001

Part name

Current (A)

L8

LF

L3

Cooling fan motor No.1

6.6

6.6 (Except Israel)

10 (For Israel)

5.9 (Except Israel)

10 (For Israel)

Cooling fan motor No.2

6.6

6.6(Except Israel)

10 (For Israel)

8

–

10

F–1

F

F

FUEL AND EMISSION CONTROL SYSTEMS

LOCATION INDEX . . . . . . . . . . . . . F-3

INTAKE-AIR SYSTEM . . . . . . . . . . . F-3
FUEL SYSTEM . . . . . . . . . . . . . F-4
EMISSION SYSTEM. . . . . . . . . . . F-6
CONTROL SYSTEM. . . . . . . . . . . F-7

ENGINE TUNE-UP . . . . . . . . . . . . . F-8

IGNITION TIMING INSPECTION . . . . . . F-8
IDLE SPEED INSPECTION. . . . . . . . . F-8
IDLE MIXTURE INSPECTION. . . . . . . . F-9

INTAKE-AIR SYSTEM. . . . . . . . . . .. F-10

VACUUM HOSE ROUTING DIAGRAM . . . . F-10
INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION. . . . . . . F-10

VARIABLE AIR DUCT (VAD)

SHUTTER VALVE INSPECTION (L3) . . . F-12

VARIABLE AIR DUCT (VAD) CONTROL

SOLENOID VALVE INSPECTION (L3) . . .. F-13

VARIABLE AIR DUCT (VAD) CHECK VALVE

(ONE-WAY) INSPECTION (L3) . . . . . .. F-13

IDLE AIR CONTROL (IAC) VALVE

INSPECTION . . . . . . . . . . . . .. F-13

VARIABLE INTAKE-AIR SYSTEM (VIS)

SHUTTER VALVE ACTUATOR
INSPECTION (L3). . . . . . . . . . ... F-14

VARIABLE INTAKE-AIR SYSTEM (VIS)

CONTROL SOLENOID VALVE
INSPECTION (L3). . . . . . . . . . ... F-14

VARIABLE TUMBLE CONTROL SYSTEM (VTCS)

SHUTTER VALVE ACTUATOR
INSPECTION . . . . . . . . . . . . .. F-15

VARIABLE TUMBLE CONTROL

SOLENOID VALVE INSPECTION. . . . .. F-15

ACCELERATOR PEDAL

REMOVAL/INSTALLATION. . . . . . . F-16

ACCELERATOR CABLE

INSPECTION/ADJUSTMENT. . . . . . . F-16

FUEL SYSTEM . . . . . . . . . . . . . . F-17

BEFORE REPAIR PROCEDURE . . . . . .. F-17
AFTER REPAIR PROCEDURE. . . . . . . F-17
FUEL TANK REMOVAL/INSTALLATION . . .. F-18
FUEL TANK INSPECTION . . . . . . . . F-19
NONRETURN VALVE INSPECTION . . . . F-20
FUEL LINE PRESSURE INSPECTION . . . . F-20
FUEL PUMP UNIT

REMOVAL/INSTALLATION. . . . . . . F-22

FUEL PUMP UNIT

DISASSEMBLY/ASSEMBLY . . . . . . .. F-24

FUEL PUMP UNIT INSPECTION . . . . . .. F-25
FUEL INJECTOR

REMOVAL/INSTALLATION. . . . . . . F-28

FUEL INJECTOR INSPECTION . . . . . . F-31
PRESSURE REGULATOR INSPECTION . . . F-34
PULSATION DAMPER

REMOVAL/INSTALLATION. . . . . . . F-34

PULSATION DAMPER INSPECTION . . . ... F-34

EXHAUST SYSTEM . . . . . . . . . . . . F-35

EXHAUST SYSTEM INSPECTION . . . . ... F-35

EXHAUST SYSTEM

REMOVAL/INSTALLATION . . . . . . . F-35

EMISSION SYSTEM . . . . . . . . . . . . F-38

CHARCOAL CANISTER INSPECTION . . . . F-38
EVAPORATIVE GAS CHECK VALVE

(ONE-WAY) INSPECTION (L.H.D.) . . . . F-38

PURGE SOLENOID VALVE

REMOVAL/INSTALLATION . . . . . . . F-38

PURGE SOLENOID VALVE INSPECTION . ... F-39
EGR VALVE REMOVAL/INSTALLATION. . .. F-39
EGR VALVE INSPECTION. . . . . . . . F-40
PCV VALVE INSPECTION . . . . . . . . F-41
THREE-WAY CATALYTIC CONVERTER (TWC)

INSPECTION . . . . . . . . . . . . .. F-41

CONTROL SYSTEM. . . . . . . . . . . . F-43

PCM REMOVAL/INSTALLATION . . . . . .. F-43
PCM INSPECTION . . . . . . . . . . . F-45
PCM CONFIGURATION . . . . . . . . . F-50
INTAKE AIR TEMPERATURE (IAT)

SENSOR INSPECTION . . . . . . . . .. F-50

MASS AIR FLOW (MAF) SENSOR

INSPECTION . . . . . . . . . . . . .. F-51

THROTTLE POSITION (TP) SENSOR

INSPECTION . . . . . . . . . . . . .. F-51

MANIFOLD ABSOLUTE PRESSURE

(MAP) SENSOR INSPECTION. . . . . ... F-52

ENGINE COOLANT TEMPERATURE

(ECT) SENSOR REMOVAL/INSTALLATION . F-53

ENGINE COOLANT TEMPERATURE

(ECT) SENSOR INSPECTION . . . . . ... F-53

CRANKSHAFT POSITION (CKP)

SENSOR INSPECTION . . . . . . . . .. F-54

CRANKSHAFT POSITION (CKP)

SENSOR REMOVAL/INSTALLATION. . . F-54

CAMSHAFT POSITION (CMP)

SENSOR INSPECTION . . . . . . . . .. F-55

KNOCK SENSOR INSPECTION . . . . . ... F-56
KNOCK SENSOR REMOVAL/INSTALLATION . F-56
HEATED OXYGEN SENSOR

(HO2S) INSPECTION . . . . . . . . . . F-56

POWER STEERING PRESSURE

(PSP) SWITCH INSPECTION . . . . . . F-58

CLUTCH SWITCH INSPECTION . . . . . .. F-59
NEUTRAL SWITCH INSPECTION . . . . . F-59
BAROMETRIC PRESSURE (BARO)

SENSOR INSPECTION . . . . . . . . .. F-60

ON-BOARD DIAGNOSTIC . . . . . . . . ... F-61

FOREWORD. . . . . . . . . . . . . .. F-61
OBD PENDING TROUBLE CODES . . . . .. F-62
OBD FREEZE FRAME DATA . . . . . . . F-62
OBD ON-BOARD SYSTEM

READINESS TEST . . . . . . . . . . . F-62

OBD DIAGNOSTIC MONITORING

TEST RESULTS . . . . . . . . . . . . F-62

OBD READ/CLEAR DIAGNOSTIC

TEST RESULTS . . . . . . . . . . . . F-62

OBD PARAMETER IDENTIFICATION

(PID) ACCESS . . . . . . . . . . . . F-62

ON-BOARD DIAGNOSTIC TEST . . . . . .. F-62

F–2

OBD DRIVE MODE. . . . . . . . . . . F-64
DIAGNOSTIC MONITORING TEST RESULTS. F-65
DTC CONFIRMATION PROCEDURE . . . ... F-66
KOEO/KOER SELF-TEST . . . . . . . . . F-66
AFTER REPAIR PROCEDURE . . . . . . . F-66
DTC TABLE . . . . . . . . . . . . . ... F-67
DTC P0010 . . . . . . . . . . . . . . F-70
DTC P0011 . . . . . . . . . . . . . . F-72
DTC P0012 . . . . . . . . . . . . . . F-73
DTC P0031 . . . . . . . . . . . . . . F-74
DTC P0032 . . . . . . . . . . . . . . F-76
DTC P0037 . . . . . . . . . . . . . . F-78
DTC P0038 . . . . . . . . . . . . . . F-80
DTC P0101 . . . . . . . . . . . . . . F-81
DTC P0102 . . . . . . . . . . . . . . F-83
DTC P0103 . . . . . . . . . . . . . . F-85
DTC P0107 . . . . . . . . . . . . . . F-86
DTC P0108 . . . . . . . . . . . . . . F-88
DTC P0111 . . . . . . . . . . . . . . F-90
DTC P0112 . . . . . . . . . . . . . . F-91
DTC P0113 . . . . . . . . . . . . . . F-92
DTC P0117 . . . . . . . . . . . . . . F-94
DTC P0118 . . . . . . . . . . . . . . F-96
DTC P0121 . . . . . . . . . . . . . . F-98
DTC P0122 . . . . . . . . . . . . . .. F-100
DTC P0123 . . . . . . . . . . . . . .. F-102
DTC P0125 . . . . . . . . . . . . . .. F-104
DTC P0131, P0132 . . . . . . . . . . .. F-105
DTC P0133 . . . . . . . . . . . . . .. F-108
DTC P0134 . . . . . . . . . . . . . .. F-110
DTC P0138 . . . . . . . . . . . . . .. F-112
DTC P0140 . . . . . . . . . . . . . .. F-114
DTC P0171 . . . . . . . . . . . . . .. F-116
DTC P0172 . . . . . . . . . . . . . .. F-119
DTC P0300 . . . . . . . . . . . . . .. F-121
DTC P0301, P0302, P0303, P0304 . . . . . F-124
DTC P0327 . . . . . . . . . . . . . .. F-126
DTC P0328 . . . . . . . . . . . . . .. F-128
DTC P0335 . . . . . . . . . . . . . .. F-130
DTC P0340 . . . . . . . . . . . . . .. F-132
DTC P0403 . . . . . . . . . . . . . .. F-134
DTC P0420 . . . . . . . . . . . . . .. F-137
DTC P0443 . . . . . . . . . . . . . .. F-138
DTC P0480 . . . . . . . . . . . . . .. F-140
DTC P0500 . . . . . . . . . . . . . .. F-142
DTC P0505 . . . . . . . . . . . . . .. F-144
DTC P0506 . . . . . . . . . . . . . .. F-145
DTC P0507 . . . . . . . . . . . . . .. F-147
DTC P0511 . . . . . . . . . . . . . .. F-148
DTC P0550 . . . . . . . . . . . . . .. F-150
DTC P0602 . . . . . . . . . . . . . .. F-152
DTC P0610 . . . . . . . . . . . . . .. F-152
DTC P0661 . . . . . . . . . . . . . .. F-153
DTC P0662 . . . . . . . . . . . . . .. F-154
DTC P0703 . . . . . . . . . . . . . .. F-156
DTC P0704 . . . . . . . . . . . . . .. F-158
DTC P0850 . . . . . . . . . . . . . .. F-160
DTC P1410 . . . . . . . . . . . . . .. F-162
DTC P1562 . . . . . . . . . . . . . .. F-164
DTC P2006 . . . . . . . . . . . . . .. F-166
DTC P2009 . . . . . . . . . . . . . .. F-168
DTC P2010 . . . . . . . . . . . . . .. F-170
DTC P2228 . . . . . . . . . . . . . .. F-172
DTC P2229 . . . . . . . . . . . . . .. F-174
DTC P2502 . . . . . . . . . . . . . .. F-176

DTC P2503. . . . . . . . . . . . . ... F-177
DTC P2504. . . . . . . . . . . . . ... F-178

TROUBLESHOOTING. . . . . . . . . . F-181

ENGINE SYMPTOM TROUBLESHOOTING ... F-181
QUICK DIAGNOSTIC CHART . . . . . . . F-182
NO.1 MELTING OF MAIN OR

OTHER FUSES. . . . . . . . . . . . F-186

NO.2 MIL ILLUMINATES . . . . . . . . . F-186
NO.3 WILL NOT CRANK . . . . . . . . . F-187
NO.4 HARD TO START/LONG

CRANK/ERRATIC START/ERRATIC
CRANK. . . . . . . . . . . . . . .. F-189

NO.5 ENGINE STALLS-AFTER

START/AT IDLE . . . . . . . . . . . F-191

NO.6 CRANKS NORMALLY BUT WILL

NOT START . . . . . . . . . . . . .. F-195

NO.7 SLOW RETURN TO IDLE . . . . . .. F-198
NO.8 ENGINE RUNS

ROUGH/ROLLING IDLE . . . . . . . ... F-199

NO.9 FAST IDLE/RUNS ON . . . . . . . F-201
NO.10 LOW IDLE/STALLS DURING

DECELERATION . . . . . . . . . . .. F-202

NO.11 ENGINE STALLS/QUITS,

ENGINE RUNS ROUGH, MISSES,
BUCK/JERK, HESITATION/STUMBLE,
SURGES . . . . . . . . . . . . . ... F-204

NO.12 LACK/LOSS OF

POWER-ACCELERATION/CRUISE . . . . F-207

NO.13 KNOCKING/

PINGING-ACCELERATION/CRUISE . . ... F-210

NO.14 POOR FUEL ECONOMY. . . . . .. F-211
NO.15 EMISSION COMPLIANCE. . . . . F-213
NO.16 HIGH OIL CONSUMPTION

/LEAKAGE . . . . . . . . . . . . . F-214

NO.17 COOLING SYSTEM

CONCERNS-OVERHEATING . . . . . .. F-215

NO.18 COOLING SYSTEM

CONCERNS-RUNS COLD . . . . . . ... F-216

NO.19 EXHAUST SMOKE . . . . . . . ... F-217
NO.20 FUEL ODOR (IN ENGINE

COMPARTMENT) . . . . . . . . . . . F-218

NO.21 ENGINE NOISE . . . . . . . . . F-219
NO.22 VIBRATION CONCERNS (ENGINE). F-220
NO.23 A/C DOES NOT WORK

SUFFICIENTLY. . . . . . . . . . . . F-220

NO.24 A/C IS ALWAYS ON OR A/C

COMPRESSOR RUNS CONTINUOUSLY ... F-221

NO.25 A/C IS NOT CUT OFF UNDER

WIDE OPEN THROTTLE CONDITIONS . .. F-221

NO.26 EXHAUST SULPHUR SMELL . . . .. F-222
NO.27 CONSTANT VOLTAGE . . . . . . F-223
NO.28 SPARK PLUG CONDITION. . . . .. F-225
INTERMITTENT CONCERN

TROUBLESHOOTING . . . . . . . . .. F-227

ENGINE CONTROL SYSTEM

OPERATION INSPECTION . . . . . . .. F-229

LOCATION INDEX

F–3

F

INTAKE-AIR SYSTEM

A6E390013000W01

.

LOCATION INDEX

A6E3910W018

1

Air cleaner
(See

F–10 INTAKE-AIR SYSTEM REMOVAL/

INSTALLATION

)

2

IAC valve
(See

F–13 IDLE AIR CONTROL (IAC) VALVE

INSPECTION

)

3

VIS control solenoid valve (L3)
(See

F–14 VARIABLE INTAKE-AIR SYSTEM (VIS)

CONTROL SOLENOID VALVE INSPECTION (L3)

)

4

Variable tumble control solenoid valve
(See

F–15 VARIABLE TUMBLE CONTROL

SOLENOID VALVE INSPECTION

)

5

VAD shutter valve (L3)
(See

F–12 VARIABLE AIR DUCT (VAD) SHUTTER

VALVE INSPECTION (L3)

)

6

VAD control solenoid valve (L3)
(See

F–13 VARIABLE AIR DUCT (VAD) CONTROL

SOLENOID VALVE INSPECTION (L3)

)

7

VIS shutter valve actuator (L3)
(See

F–14 VARIABLE INTAKE-AIR SYSTEM (VIS)

SHUTTER VALVE ACTUATOR INSPECTION (L3)

)

8

VTCS shutter valve actuator
(See

F–15 VARIABLE TUMBLE CONTROL

SYSTEM (VTCS) SHUTTER VALVE ACTUATOR
INSPECTION

)

9

VAD Check valve (one-way) (L3)
(See

F–13 VARIABLE AIR DUCT (VAD) CHECK

VALVE (ONE-WAY) INSPECTION (l3)

)

10

Accelerator pedal (R.H.D.)
(See

F–16 ACCELERATOR PEDAL REMOVAL/

INSTALLATION

)

11

Accelerator cable (R.H.D.)
(See

F–16 ACCELERATOR PEDAL REMOVAL/

INSTALLATION

)

12

Accelerator pedal (L.H.D.)
(See

F–16 ACCELERATOR PEDAL REMOVAL/

INSTALLATION

)

13

Accelerator cable (L.H.D.)
(See

F–16 ACCELERATOR PEDAL REMOVAL/

INSTALLATION

)